Oriented Elastomeric Load Surface to Prevent Hammocking
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Solution Overview
Problem
Existing load bearing surfaces, such as seating and bed surfaces, often lack durability, comfort, and tunability to provide optimal support characteristics, with molded plastic surfaces offering limited ergonomic support and elastomeric fabrics experiencing undesirable 'hammocking' that reduces comfort.
Innovation Solution
A decoupled elastomeric load bearing surface is created by orienting a molded elastomeric membrane to increase crystalline structure alignment in one direction, reducing creep and allowing for varying elasticity in different directions, and incorporating mechanical structures like slits, channels, or nodes to provide 'slack' and adjust support characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molded plastic surfaces are used to provide an inexpensive seating option, then cost is reduced, but comfort and ergonomic support deteriorate due to linear force/deflection profile
Solution Approach 1:
The patent changes the force/deflection parameter from linear to non-linear by using an elastomeric membrane with controlled orientation. The membrane is stretched or compressed during manufacturing to align crystalline structures, creating a non-linear force/deflection profile that provides progressive resistance and improved comfort while maintaining low cost through single-material construction
Solution Approach 2:
The patent creates a composite structure by combining elastomeric material with a oriented crystalline structure within a single membrane. This internal composite approach provides both the cost benefits of molded plastic and the comfort benefits of progressive resistance, eliminating the need for separate cushion layers
2Ease of operation
If elastomeric fabrics are used to provide comfortable and ventilated seating, then comfort is improved, but support characteristics deteriorate due to hammocking effect
Solution Approach 1:
The patent changes the structural parameter of the elastomeric material by controlling crystalline orientation during manufacturing. By stretching or compressing the membrane to align molecular structures in specific directions, the patent creates anisotropic properties that prevent hammocking while maintaining comfort, providing directional support characteristics
Solution Approach 2:
The patent applies different structural properties in different directions within the same membrane. The crystalline orientation creates regions with different elasticity and support characteristics, providing firm support in the vertical direction while allowing controlled deflection in horizontal directions, eliminating the hammocking effect
3Reliability
If molded elastomeric membrane is oriented to increase crystalline structure alignment, then creep resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies orientation treatment during the molding process itself, rather than as a separate post-processing step. By incorporating the orientation action into the primary manufacturing operation, the patent achieves creep resistance without adding significant manufacturing complexity, as the membrane is oriented while still in a pliable state during molding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a strong, flexible, and ventilated load bearing surface that is cost-effective, comfortable, and customizable to different applications, reducing material thickness and weight while enhancing support and comfort by controlling elasticity and creep resistance.
Implementation Method 1
the molded elastomeric membrane may be oriented by compressing or stretching the membrane in one direction to the extent necessary to increase the alignment of the crystalline structure of the elastomer
Implementation Method 2
The orientation process varies the support characteristics of the membrane resulting in a membrane with significant elasticity in the direction of orientation and a low level of creep
Data Source
AI summary
An elastomeric load bearing surface with different load support characteristics in different directions. In one embodiment, the surface includes an elastomeric membrane that is oriented in only a single direction, for example, by compression or stretching. In another embodiment, the surface includes mechanical structures, such as connectors and variations in thickness that vary the load support characteristics in different directions. In another embodiment, a surface is both oriented and includes mechanical structures.